ROOM AIR CONDITIONER - Dunham-Bush Africa - Home€¦ · CONTENTS SAFETY PRECAUTIONS 2 INSTALLATION OF INDOOR AND OUTDOOR UNITS 3 ELECTRICAL WORK 9 AIR PURGING

(Inverter Split Type)

Please read this installation manual completely before installing the product.

When the power cord is damaged, replacement work shall be performed by authorized personnel only.

Installation work must be performed in accordance with the national wiring standards by authorized personnel only.

Contact the authorised service technician for repair or maintenance of this unit.

ROOM AIR CONDITIONER

INSTALLATION MANUAL

CONTENTS

SAFETY PRECAUTIONS...................................................................2

INSTALLATION OF INDOOR AND OUTDOOR UNITS.......................3

ELECTRICAL WORK ........................................................................9

AIR PURGING ..................................................................................

TEST RUNNING...............................................................................

1 Contents

11

13

! WARNING

Do not install, remove and reinstall the unit by yourself.

Improper installation will cause water leakage, electrical shock, or fire. Please consult authorized dealer or specialist for the installation work. Please note fault caused by improper installation is not covered by warranty.Unit must be installed in an easily accessible area. Any additional cost required to hire a special equipment to service the unit will be the responsibility of the customer.

2 Safety precautions

! WARNING

Do not install it yourself.

Install the unit securely in a place whichcan bear the weight of the unit.

Use the specified wires to connect the indoor and outdoor units securely andattach the wires firmly to the terminalboard connecting sections so the stressof the wires is not applied to the sections

Incorrect installation could cause injury due to fire, electric shock, the unit falling or leakage of water. Consult the dealer from whom you purchased the unit or special installer

When installed in an insufficiently strong place, the unit could fall causing injury.

Incorrect connection and fixing could cause a fire.

If the capacity of the power circuit is insufficient or there is incomplete electrical work, it could result in a fire or an electric shock.

The use of defective parts could cause an injury due to a fire, electric shock, the unit falling, etc.

Incorrect installation could cause a personnel injury due to fire, electric shock, the unit falling or leakage of water.

If the electrical part covers of the outdoor unit and/or the service panel of the indoor unit are not attached securely, it could result in a fire or electrical shock due to dust, water, etc.

Perform electrical work according to the installation manual and be sure to use an exclusive circuit.

Be sure to use the part provided or specified parts for the installation work.

Perform the installation securely referring to the installation instruction.

Check that the refrigerant gas does notleak after installation is completed.

Attach the electrical part cover to the outdoor unit and the service panel to the indoor unit securely.

Be sure to read the following WARNING before installing the air conditioner.

Be sure to observe the cautions specified here as they include important items related to safety.

After reading this instructions, be sure to keep it together with the owners manual in a handy place for future reference.

SAFETY PRECAUTIONS

The following should be always observed for safety:

! CAUTIONS

Do not install the unit in a place wherea flammable gas leaks.

If gas leaks and accumulates in the area surrounding the unit, it could cause a explosion.

If there is a defect in the drainage/piping work, water could leak from the unit and household goods could get wet and be damaged.

Perform the drainage/piping work according to the installation instruction.

3 Installation Instruction

INSTALLATION OF INDOOR AND OUTDOOR UNITS

Read completely, then follow step by step.

Indoor unitDo not expose the indoor unit to heat or steam.Select a place where there are no obstacles in front or around the unit.Make sure that condensation drainage can be conveniently routed away.Do not install near a doorway.Ensure that the space on the left and right of the unit is more than 12cm. Use a stud finder to locate studs to prevent unnecessary damage to the wall. A minimum pipe run of 3 metres is required to minimise vibration & excessive noise.The indoor unit should be installed on the wall at a height of 2.3 metres or more from the floor. The indoor unit should be installed allowing a minimum clearance of 15cm from the ceiling.Any variations in pipe length will/may require adjustment to refrigerant charge.There should not be any direct sunlight. Otherwise, the sun will fade the plastic cabinet and affect its appearance. If unavoidable, sunlight prevention should be taken into consideration.

Outdoor unitIf an awning is built over the outdoor unit to prevent direct sunlight or rain exposure, make sure that heat radiation from the condenser is not restricted.Ensure that the clearance around the back of the unit is more than 30cm and left side is more than 30cm. The front of the unit should have more than 200cm of clearance and the connection side (right side) should have morethan 60cm of clearance.Do not place animals and plants in the path of the air inlet or outlet.Take the air conditioner weight into account and select a place where noise and vibration will not be an issue.Select a place so that the warm air and noise from the air conditioner do not disturb neighbors.

If the outdoor unit is installed on a roof structure, be sure to level the unit. Ensure the roof structure and anchoring method are adequate for the unit location.Consult local codes regarding rooftop mounting.If the outdoor unit is installed on roof structures or external walls, this may result in excessive noise and vibration, and may also be classed as a non serviceable installation.

More than 30cm

More than 60cm

More than 30cm

More than 200cm

Rooftop installation:

2.3m or more

More than 15cm

More than 12cm

More than 12cm

Fig.1

1

2

3

4

5

6

7

1

1

1

8

8

1

Parts you must purchase (A Minimum pipe wall- thickness of 0.7mm is required)

Note: Except the above parts provided, the other parts needed during installation you must purchase.

Mounting screw B

ST2.9x10-C-H

Remote controller

holder

This illustration is for explanation purposes only. Copper lines must be insulated independently


Items packed with the unit

6.35

9.53

12.7

8 2

Loop theconnectivecable.

Self-tapping Screw B ST2.9X10

Fig.3

Remote controller

Installation Plate

Name of Accessories

Self-tapping Screw A ST3.9X25

Seal

Drain Joint

Connecting pipeAssembly

Liquid side

Clip Anchor

Number Q ty

Gas side

9 Remote controller holder1

8

9

Remote Controller

7

Ensure that the space around the left and right of the indoor unit is more than 12cm.The indoor unit should be installed allowinga minimum clearance of 15cm from the ceiling.Use a stud finder to locate studs to prevent unnecessary damage to the wall. A minimum pipe run of 3 metres is required to minimise vibration & excessive noise.The indoor unit should be installed on the wall at a height of 2.3 metres or more from the floor .At lease two of the Directions A, B and C should be free from obstructions.

CAUTION

C

B

A

60cm above

60cm

above

30cm above

200cm above

6

23

1

12cm above

12cm above

Air Filter

15cm above

Air Outlet

30cm above

( 12000Btu/h model)

( 12000Btu/h model)

On/Off

Sleep

Fan

Swing

Air Direction

Timer On

Timer Off

Mode

Hr.

ON TIMER

Hr.

Off TIMER

SET TEMP

Auto


INDOOR UNIT INSTALLATION

1.

2. Drill a hole in the wall

Fig.4

Fig.5

Note:

Fit the Installation Plate

1. Fit the installation plate horizontally on structural parts of the wall with spaces around the installation plate.2. If the wall is made of brick, concrete or the like, drill eight (8) 5mm diameter holes in the wall. Insert Clip anchor for appropriate mounting screws.3. Fit the installation plate on the wall with eight (8) type “A” screws.

Correct orientation of Installation Plate

Fit the Installation Plate and drill holes in the wall according to the wall structure and corresponding mounting points on the installation plate.(Dimensions are in “mm” unless otherwise stated)

1. Determine hole positions according to the diagram detailed in Fig.5. Drill one (1) hole ( 65mm) slanting slightly to outdoor side.2. Always use wall hole conduit when drilling metal grid, metal plate or the like.

Wall

IndoorOutdoor

5-7

mm

Fig.6

A

40

B

Right rear side refrigerantpipe hole 65

Installation plateIndoor unit outline

Left rear side refrigerantpipe hole 65

150mm or more to ceiling

120mm or moreto wall


( 12000Btu/h model)

<12000Btu/h model: (A: 710, B: 250)12000Btu/h model: (A: 790, B:265)

90

40

45

150mm or more to ceiling

Indoor unit outlineInstallation plate

293

Right rear side refrigerantpipe hole 65

Left rear side refrigerantpipe hole 65



920

45

9045

45

27

2

80489


1. For the left-hand and right-hand piping, remove the pipe cover from the side panel.

Explain to clients that the pipe cover must be kept as it may be used when relocate the

air conditioner to any other place.

2. For the rear-right-hand and rear-left-hand piping, install the piping as shown. Bend the

connective pipe to be laid at 43mm height or less from the wall.

3. Fix the end of the connective pipe. (Refer to Tightening Connection in REFRIGERANT

PIPING CONNECTION)

Connective pipe

Indoor unit outlineConnective pipe

........ ......... .. .. .... .. .. ...

. . .. . ... ...... .. .. . .... .. . .. . ...... .. . .

.... .. . .... ....

.. ... .. .. . ... .. .... .. ...

. .

.. . .... .. . .

.....

..... ...

... . ..

... .......... .4

3

1. Pass the piping through the hole in the wall.

2. Put the upper claw at the back of the indoor unit on

the upper hook of the installation plate, move the

indoor unit from side to side to see that it is securely

hooked.

3. Piping can easily be made by lifting the indoor unit

with a cushioning material between the indoor unit

and the wall. Get it out after finish piping.

4. Push the lower part of the indoor unit up on the wall,

Then move the indoor unit from side to side, up and

down to check if it is hooked securely.Fig.9

4. Indoor unit installationFig.7

Fig.8

3. Connective Pipe and Drainage Installation

1. Run the drain hose sloping downward. Do not install the drain hose as illustrated

below.

2. When connecting extension drain hose, insulate the connecting part of extension

drain hose with a shield pipe, do not let the drain hose slack.

Drainage

Fig.6

Do not block water flow by a rise.Do not put the end of drain hose into water.

Pipe holder

Pipe Cover (right)

Pipe Cover (left)

Right piping

Left piping

Right back piping

Left back piping

Upper Hook

Lower Hook

Cushioning

material


5. Piping and wrapping

Bundle the tubing, connecting cable, and

drain hose with tape securely,

evenly as shown in Fig.10.

Because the condensed water from rear

of the indoor unit is gathered in ponding

box and is piped out of room. Do not put

anything else in the box.

Indoor unit

Connectivepipe

Pipe room

Ponding box

Wrapping belt

Connectivecable

Drain hose

Fig.10

Connect the indoor unit first, then the outdoor unit.

Do not allow the piping to let out from the back of the indoor unit.

Be careful not to let the drain hose slack.

Heat insulated both of the auxiliary piping.

Be sure that the drain hose is located at the lowest side of the bundle. Locating

at the upper side can cause drain pan to overflow inside the unit.

Never intercross nor intertwist the power wire with any other wiring.

Run the drain hose sloped downward to drain out the condensed water smoothly.

CAUTION

Install the outdoor unit on a rigid base to prevent increasing noise level and vibration.

Determine the air outlet direction where the discharged air is not blocked.

In the case that the installation place is exposed to strong wind such as a seaside,

make sure the fan operating properly by putting the unit lengthwise along the wall

or using a dust or shield plates.

Specially in windy area, install the unit to prevent the admission of wind.

If need suspending installation, the installation bracket should accord with technique

requirement in the installation bracket diagram. The installation wall should be solid

brick, concrete or the same intensity construction,

or actions to reinforce, damping supporting should

be taken. The connection between bracket and

wall, bracket and the air conditioner should be

firm, stable and reliable.

Be sure there is no obstacle which block

radiating air.

OUTDOOR UNIT INSTALLATION

Outdoor installation precaution

Strong wind

Fig.11


Settlement of outdoor unit

Anchor the outdoor unit with

a bolt and nut 10 or 8 tightly

and horizontally on a concrete

or rigid mount.

Fit the seal into the drain elbow, then insert

the drain joint into the base pan hole of

outdoor unit, rotate 90 to securely assemble

them. Connecting the drain joint with an

extension drain hose (Locally purchased),

in case of the water draining off the outdoor unit

during the heating mode.

Drain joint installation

Seal Drain joint Base pan hole ofoutdoor unit

Seal

Drain pipe

Fig.13

REFRIGERANT PIPING CONNECTION

Oblique90 C Roughness Burr

Main cause for refrigerant leakage

is due to defect in the flaring work.

Carry out correct flaring work

using the following procedure:

A: Cut the pipes and the cable.

1. Use the piping kit accessory or pipes

purchased locally.

2. Measure the distance between the indoor and the outdoor unit.

3. Cut the pipes a little longer than the measured distance.

4. Cut the cable 1.5m longer than the pipe length.

1. Flaring work

Fig.14

A

B

Air inlet

Air outlet

Air inlet

Fig.12

B: Burr removal1. Completely remove all burrs from the cut cross section of pipe/tube.2. Put the end of the copper tube/pipe in a downward direction as you remove burrs in order to avoid dropping burrs into the tubing.

Pipe

Reamer

Point down

Fig.15

Outdoor unit dimension

mm(WxHxD) A(mm)

458

460

B(mm)

250

276

530 290

560 335

549 276

Mounting dimensions

700x535x235

685x430x260

780x540x250

760x590x285

845x695x335

Bar

Copper pipe

Clamp handleRed arrow mark

Cone

Yoke

Handle

Bar"A"

C: Putting nut on Remove flare nuts attached to indoor and outdoor unit, then put them on pipe/tube having completed burr removal.(not possible to put them on after flaring work)

Flare nut

Copper tube

Fig.16

Fig.17

D: Flaring work

Firmly hold copper pipe in a die in the dimension shown in the table below.

CAUTION

Align the center of the pipes..Sufficiently tighten the flare nut with fingers, and then tighten it with a spanner and torque wrench as shown.

Tightening Connection

Excessive torque can break nut depending on installation conditions.

Outerdiam.

Tighteningtorque(N.cm)

Additional tighteningtorque(N.cm)

6.351570

(160kgf.cm)1960

(200kgf.cm)

4900(500kgf.cm)

5390(550kgf.cm)12.7

Outer diam.(mm)

A(mm)

Max. Min.

6.35 1.3 0.7

9.53 1.6 1.0

12.7 1.8 1.0

9.532940

(300kgf.cm)3430

(350kgf.cm)

Fig.19

Indoor unit tubing Flare nut Pipings

Fig.18

ELECTRICAL WORK

Electric safety regulations for the initial Installation1. If there is serious safety problem about the power supply, the technicians should refuse to install the air conditioner and explain to the client until the problem is solved. 2. Power voltage should be in the range of 90%~110%of rated voltage.3. The creepage protector and main power switch with a 1.5 times capacity of Max. Current of the unit should be installed in power circuit.4. Ensure the air conditioner is grounded well.

7. An individual branch circuit and single receptacle used only for this air conditioner must be available. See the following table for suggested wire sizes and fuse specifications:

5. According to the attached Electrical Connection Diagram located on the panel of the outdoor unit to connect the wire.

6. All wiring must comply with local and national electrical codes and be installed by qualified and skilled electricians.

9 Electrical work

12.7 1.8 1.0

Model Power supply Input Rated Amp

(Switch/Fuse)

NOTE: The supply voltage should be consistent with the rated voltage

of the air conditioner.

16A

25A

Connect the cable to the indoor unit1. Indoor/Outdoor connection cable should be H07RN-F type.2. Remove the panel and Screw, then remove the window cover.3. Connect cables according to their marks to terminals.4. Wrap those cables not connected with terminals with insulation tapes, so that they will not touch any electrical components.

10mm 40mm

Terminal block of indoor unit

To outdoor unitTo outdoor unit

Cord clamp

L N S L N S

Connect the cable to the outdoor unit

1. Remove the electric parts cover from the outdoor unit.2. Connect the connective cables to the terminals as identified with their respective matched numbers on the terminal block of indoor and outdoor units.3. To prevent the ingress of water, from a loop of the connective cable as illustrated in the installation diagram of indoor and outdoor units.4. Insulate unused cords (conductors) with PVC-tape.Process them so they do not touch any electrical or metal parts.

Cover

Screw40mm10mm

10 Electrical work

Fig.20

Fig.21

220-240V~ 50Hz or 220-230V~60Hz

Window cover

Panel

12000Btu/h

12000Btu/h

12000Btu/h 12000Btu/h

Minimum norminal cross-sectional area of conductors:

Rated current of appliance (A)

>3 and <6>6 and <10

>10 and <16

>16 and <25

Nominal cross-sectional area

2 (mm )

0.751

1.52.5

L S N

Wire connector of outdoor unit

Wire -holding board

L S N

or

11Air purging

After the confirmation of the above conditions, prepare the wiring as follows:

1) Never fail to have an individual power circuit specifically for the air conditioner. As forthe method of wiring, be guided by the circuit diagram posted on the inside of controlcover.

2) The screw which fasten the wiring in the casing of electrical fittings are liable to comeloose from vibrations to which the unit is subjected during the course oftransportation. Check them and make sure that they are all tightly fastened. (If theyare loose, it could cause burn-out of the wires.)

3) Specification of power source.

4) Confirm that electrical capacity is sufficient.

5) See to that the starting voltage is maintained at more than 90 percent of the ratedvoltage marked on the name plate.

6) Confirm that the cable thickness is as specified in the power source specification.7) Always install an earth leakage circuit breaker in a wet or moist area.

8) The following would be caused by voltage drop.

¥

Vibration of a magnetic switch, which will damage the contact point, fuse breaking, disturbance of thenormal function of the overload.

9) The means for disconnection from a power supply shall be incorporated in the fixedwiring and have an air gap contact separation of at least 3mm in each active(phase)conductors.

CAUTIONCAUTION CAUTIONCAUTION

AIR PURGING

Air and moisture in the refrigerant system have undesirable effects as indicated below: Pressure in the system rises. Operating current rises. Cooling or heating efficiency drops. Moisture in the refrigerant circuit may freeze and block capillary tubing. Water may lead to corrosion of parts in the refrigeration system.

Therefore, the indoor unit and tubing between the indoor and outdoor unit must be leak tested and evacuated to remove any noncondensables and moisture from the system.

Air purging with vacuum pumpPreparationCheck that each tube(both liquid and gas side tubes) between the indoor and outdoor units have been properly connected and all wiring for the test run has been completed. Remove the service valve caps from both the gas and the liquidside on the outdoor unit. Note that both the liquid and the gas side service valves on the outdoor unit are kept closed at this stage.

Pipe length and refrigerant amount:

Connectivepipe length

Less than 5m

More than 5m

Air purgingmethod

Use vacuumpump.

Use vacuumpump.

Additional amount of refrigerant to be charged

R22: (Pipe length-5)x30g/mR410A: (Pipe length-5)x20g/m

12 Air purging

When relocate the unit to another place, perform evacuation using vacuum pump.

Make sure the refrigerant added into the air conditioner is liquid form in any case.

(Not applicable to the units with R22 refrigerant)

Open the valve stem until it hits against the stopper. Do not try to open it further.

Securely tighten the valve stem cap with a spanner or the like.

Valve stem cap tightening torque (See Tightening torque table in previous page ).

Outdoorunit

Indoorunit

Refrigerant Flare nut

StopperCap

Valve body

Packed valve Half union

Gas side

Liquid side

A C

D

B

Valve stem

Fig.22 Fig.23

When Using the Vacuum Pump

(For method of using a manifold valve, refer to its operation manual.)

1. Completely tighten the flare nuts, A, B, C, D, connect the manifold valve charge

hose to a charge port of the low-pressure valve on the gas pipe side.

2. Connect the charge hose connection to the vacuum pump.

3. Fully open the handle Lo of the manifold valve.

4. Operate the vacuum pump to evacuate. After starting evacuation, slightly loose the

flare nut of the Lo valve on the gas pipe side and check that the air is entering

(Operation noise of the vacuum pump changes and a compound meter indicates

0 instead of minus)

5. After the evacuation is complete, fully close the

handle Lo of the manifold valve and stop the

operation of the vacuum pump.

Make evacuation for 15 minutes or more and

check that the compound meter indicates

-76cmHg (-1x10 Pa).o6. Turn the stem of the packed valve B about 45

counterclockwise for 6~7 seconds after the gas

coming out, then tighten the flare nut again. Make

sure the pressure display in the pressure indicator

is a little higher than the atmosphere pressure.

7. Remove the charge hose from the Low pressure charge hose.

8. Fully open the packed valve stems B and A.

9. Securely tighten the cap of the packed valve.

Manifold valve

Compound meter

-76cmHg

Handle Lo Handle Hi

Charge hose Charge hose

Vacuum pump

Pressure gauge

Low pressure valve

Fig.24

Caution in handling the packed valve

5

13Test running

Perform the electric safe check after completing installation:

1. Insulated resistance

The insulated resistance must be more than 2M .

2. Grounding work

After finishing grounding work, measure the grounding resistance by visual detection and

grounding resistance tester. Make sure the grounding resistance is less than 4 .

3. Electrical leakage check (performing during test running)

During test operation after finishing installation, the serviceman can use the electroprobe

and multimeter to perform the electrical leakage check. Turn off the unit immediately if

leakage happens. Check and find out the solution ways till the unit operate properly.

A: Lo packed valve B: Hi packed valve

C and D are ends of indoor unit connection.

CAUTION

Indoor unitcheck point

D

B

C

AOutdoor unitcheck point

Cover

Fig.25

Electrical safety check

Gas leak check1. Soap water method: Apply a soap water or a liquid neutral detergent on the indoor unit connection or outdoor unit connections by a soft brush to check for leakage of the connecting points of th piping. If bubbles come out, the pipes have leakage.2. Leak detector

Use the leak detector to check for leakage.

ELECTRICAL SAFETY AND GAS LEAK CHECK

TEST RUNNING

Manual control

Button

AUTO/COOL

Perform test running after completing gas leak and electrical safety check.

The test running time should last more than 30 minutes.

1. Open the panel and lift the panel up to an angle which remains fixed. Do not lift the

panel any further when it stops with a click sound.

2. Press the manual control button twice until the operating indicator lights up, the unit

will operate on Forced Cool mode.

3. Check if all the functions works well during test running. Especially check whether

the drainage of indoor unit is smooth or not.

4. Press the manual switch button again after finishing the test running . The operating

indicator turns dark and the unit stops operating.

Documents

ROOM AIR CONDITIONER - Dunham-Bush Africa - Home€¦ · CONTENTS SAFETY PRECAUTIONS 2 INSTALLATION OF INDOOR AND OUTDOOR UNITS 3 ELECTRICAL WORK 9 AIR PURGING